Knitted fabric and method for producing a knitted fabric

ABSTRACT

Knitted fabric and method of forming knitted fabric. Knitted fabric includes warp threads that run in a longitudinal direction and that are connected to one another by a stitch formation, and at least three sections arranged consecutively in the longitudinal direction. The at least three sections may include at least one section formed as a spacer fabric, one section formed as a single-ply fabric and one section formed as a tubular fabric.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority under 35 U.S.C. §119(a) ofEuropean Patent Application No. 15 162 489.7 filed Apr. 2, 2015, thedisclosure of which is expressly incorporated by reference herein in itsentirety.

BACKGROUND

1. Field of the Invention

Embodiments of the invention relate to a knitted fabric with warpthreads, running in the longitudinal direction of the knitted fabric,connected to one another by a stitch formation.

Furthermore, embodiments of the invention relate to a method forproducing a knitted fabric in which two knitting needle heads andthread-feeding elements are used. The thread-feeding elements are atleast partially embodied as jacquard elements.

2. Discussion of Background Information

A knitted fabric is typically produced in such a manner that warpthreads that are disposed next to one another in a warp beam arrangementare drawn off from the warp beam and guided around knitting needles byguide needles in order to form stitches. To achieve a cohesion of thewarp threads to obtain a fabric, warp threads positioned adjacent to oneanother are stitched together during a stitch formation of this type.Depending on the type of connection used thereby, stitches can not onlybe formed with the most proximately adjacent warp threads, but ratheralso with the next closest or more distant warp threads. In any case,the warp threads always run in a longitudinal direction.

For the formation of knitted fabrics, there are pure fabrics that arereferred to below as a “single-ply” fabric. There are also spacerfabrics. In the case of a spacer fabric, two covering layers areprovided that are embodied as surface layers. These two covering layersare connected to one another by what are referred to as spacer threads,which are also called “pile threads”. In addition, there are what areknown as tubular fabrics. A tubular fabric is a knitted fabric with twolayers of a surface material that are only connected to one another attheir longitudinal edges. A tubular fabric can be used, for example, toform a holder, in particular a pouch or bag. Here, it is only necessaryto connect the two layers of the tubular fabric at the end of a sectionin the longitudinal direction in order to close the holder.

A spacer fabric is often used as padding material. A spacer fabric isalso often chosen where a covering that exhibits good air permeabilityis desired.

If the aim is to achieve multiple effects, it is normally necessary tofinish individual knitted fabrics that are produced on separate knittingmachines, that is, to make them the right size and then connect, e.g.,sew, them to one another. This means that the production of textileobjects that are to fulfill several functions is costly.

SUMMARY

Embodiments of the invention are directed to the production of textileobjects having multiple functions in a simple manner.

According to embodiments, a knitted fabric of the type named at theoutset includes at least one section embodied as a spacer fabric, onesection embodied as a single-ply fabric and one section embodied as atubular fabric that are arranged consecutively in the longitudinaldirection.

In a knitted fabric of this type, three different fabric types are thusarranged one after another. Because these three sections are formed fromthe same warp threads, the three sections are connected to one anotherin the longitudinal direction when they leave the knitting machine.Thus, no additional work steps are necessary to connect these sectionsto one another. At the same time, the knitted fabric has severalfunctions overall, since each section exhibits the desired andpredetermined property. The knitted fabric with the different sectionscan be manufactured using ground guide bars and jacquard bars in thatthe jacquard bars are for example used to lay down the spacer or pilethreads.

Preferably, the single-ply fabric is embodied as a one-by-one ribknitted fabric. The single-ply fabric thus comprises two covering layerspositioned on top of one another which, however, are connected to oneanother in a planar manner, so that they ultimately form only a singlelayer. A one-by-one rib knitted fabric can be easily produced on adouble-section knitting machine, so that the same knitting machine canbe used to produce both the spacer fabric and the tubular fabric, aswell as the single-ply fabric.

Preferably, the single-ply fabric is arranged between the spacer fabricand the tubular fabric. The single-ply fabric can then perform a sort ofhinge function between the spacer fabric and the tubular fabric. At thesame time, the single-ply fabric creates a connection between the twocovering layers at an end of the tubular fabric, so that the “bottom” ofa bag or pouch is formed as a result. The remaining walls (except forthe cover) are formed by the tubular fabric.

Preferably, the spacer fabric has a larger extension in the longitudinaldirection than the tubular fabric. The spacer fabric can thus be used tocover and pad the bag or pouch, which have been formed by the tubularfabric, not only on one side, but rather also additionally on the otherside, at least in sections.

Here, it is particularly preferred that the spacer fabric has anextension in the longitudinal direction that is at least two times aslarge as the extension of the tubular fabric in the longitudinaldirection. Both covering layers of the tubular fabric can thus becovered by the spacer fabric, so that a full padding of the tubularfabric is possible.

Preferably, the spacer fabric is arranged symmetrically to thesingle-ply fabric in the thickness direction. However, this symmetry isnot a symmetry in the strictly mathematical sense. Instead, it isadequate if the single-ply fabric is arranged roughly in the middle ofthe spacer fabric in the thickness direction, that is, if betweenroughly 40% and 60% of the thickness of the spacer fabric protrudes pastthe single-ply fabric in one direction and the remaining amount of thethickness protrudes in the other direction. The knitted fabric can thusbe designed relatively freely, as it is subsequently of littleimportance in which direction the spacer fabric is folded or bent inrelation to the single-ply fabric.

Preferably, the single-ply fabric has an extension in the longitudinaldirection which is at least as large as a thickness of the spacer fabricthat protrudes past the single-ply fabric. It can thus be achieved thatthe spacer fabric can be folded back directly onto the tubular fabric.It is thus in turn possible to achieve a padding for the tubular fabric,at least on one side of the tubular fabric.

Preferably, the single-ply fabric has an extension in the longitudinaldirection that is at least as large as a thickness of the tube formed bythe tubular fabric. This is also a measure for ensuring that a holderformed by the tubular fabric can be covered, and thus padded, by thespacer fabric on at least one side.

Preferably, a section with spacer fabric is arranged on one side of asection of the tubular fabric and a section with single-ply fabric isarranged on the opposite side of the tubular fabric. Thus, the spacerfabric can be folded down from the opening of the holder formed by thetubular fabric onto at least one side wall of the tubular fabric, sothat it can pad the tubular fabric in this position. Particularly if aspacer fabric is also arranged at the other end of the single-plyfabric, that is, at the end of the single-ply fabric facing away fromthe tubular fabric, both sides of the holder formed by the tubularfabric can be covered, and thus padded, with high reliability.

Preferably, the spacer fabric comprises sections with differingthicknesses transversely to the longitudinal direction. A pattern, forexample, can thus be achieved, or an eventual use of a holder that isformed by means of the tubular fabric can be accommodated. For example,the tubular fabric can be provided as a holder for a delicate object,and a larger thickness of the spacer fabric can be chosen in thelocations where the delicate object requires special protection.

Embodiments of the invention are directed to a method of the type namedat the outset that includes using at least four independentthread-feeding elements and controlling the jacquard elements so thatthey are used to form piles or to form surfaces, depending on apredetermined fabric structure.

With this method, the different fabric structures, that is, the spacerfabric, single-ply fabric and tubular fabric, can be reproduced in oneknitted fabric. This occurs in a simple manner by means of the targetedselection of needles that are to form a stitch on one or both of theneedle heads. If all of the needles that are to produce a stitch on thefront and rear needle head are chosen, a spacer fabric is formed. Ifonly the edges are closed, a tube is produced. If the frontthread-feeding elements are woven in on the rear knitting needle headand vice versa, a one-by-one rib knitted fabric is produced.

Preferably, the jacquard elements are used to pattern at least onesurface. Here, a colored thread can be used, for example, to create astructure in a multicolored textile.

It is also advantageous if jacquard elements of a single row arecontrolled varyingly during a stitch formation. It is thus possible towork the fabric structures not only in the direction of production, butalso in the width direction of the knitted fabric. The input andsequencing of the individual repeating patterns can be achieved by apattern control processor, for example.

Preferably, different structures are created in the width direction ofthe knitted fabric. Significant flexibility can thus be achieved in theproduction of the knitted fabric.

Embodiments are directed to a knitted fabric that includes warp threadsthat run in a longitudinal direction and that are connected to oneanother by a stitch formation, and at least three sections arrangedconsecutively in the longitudinal direction. The at least three sectionsmay include at least one section formed as a spacer fabric, one sectionformed as a single-ply fabric and one section formed as a tubularfabric.

In embodiments, the single-ply fabric can be formed as a one-by-one ribknitted fabric.

According to embodiments, the single-ply fabric may be arranged betweenthe spacer fabric and the tubular fabric. The spacer fabric can have alarger extension in the longitudinal direction than the tubular fabric.Further, the spacer fabric can have an extension in the longitudinaldirection that is at least two times as large as the extension of thetubular fabric in the longitudinal direction.

In accordance with other embodiments, the spacer fabric may besymmetrically arranged to the single-ply fabric in the thicknessdirection.

According to still other embodiments, the single-ply fabric may have anextension in the longitudinal direction which is at least as large as athickness of the spacer fabric that protrudes past the single-plyfabric.

In other embodiments, the single-ply fabric may have an extension in thelongitudinal direction which is at least as large as a thickness of atube that is formed by the tubular fabric.

In further embodiments, the spacer fabric can be arranged on one side ofthe tubular fabric and the single-ply fabric is arranged on an oppositeside of the tubular fabric.

According to still other embodiments, the spacer fabric may includesections with different thicknesses transversally to the longitudinaldirection.

Embodiments of the invention are directed to a method for producing aknitted fabric using two knitting needle heads and thread-feedingelements at least partially embodied as jacquard elements. The methodincludes forming piles or surfaces, depending upon a predeterminedfabric structure, by using at least four independent thread-feedingelements and controlling the jacquard elements.

In embodiments, the jacquard elements can be used to pattern at leastone surface.

According to other embodiments, the jacquard elements may be controlledvaryingly during a stitch formation process.

Moreover, different structures can be created in the width direction ofthe knitted fabric.

Embodiments of the invention are directed to a method of forming aknitted fabric. The method includes forming at least three sectionsconsecutively in a longitudinal direction along which warp threads arearranged to run, the at least three sections can include a spacer fabricsection, a single-ply fabric section and a tubular fabric section. Informing the at least three sections, the warp threads are connected toone another by a stitch formation.

In accordance with still yet other embodiments of the present invention,the spacer fabric section can include a front surface layer and a rearsurface layer connected by pile threads, the single-ply fabric sectioncan include the front surface layer and the rear surface layer, and thetubular fabric section can include the front surface layer and the rearsurface layer. In a machine with plural guide bars, a first guide barcan lay down the front surface layer, a second guide bar can lay downthe rear surface layer and a third guide bar can lay down the pilethreads. In a machine with plural guide bars and plural jacquard bars, afirst guide bar can lay down the front surface layer, a second guide barcan lay down the rear surface layer and the plural jacquard bars can laydown the pile threads. Moreover, in a machine with at least two needlebeds and plural independent thread-feeding elements, the at least twoneedle beds can form the front and rear surface layer and the pluralindependent thread-feeding elements can form the pile layers. The pluralindependent thread-feeding elements may include at least four jacquardbars.

Other exemplary embodiments and advantages of the present invention maybe ascertained by reviewing the present disclosure and the accompanyingdrawing.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is further described in the detailed descriptionwhich follows, in reference to the noted plurality of drawings by way ofnon-limiting examples of exemplary embodiments of the present invention,in which like reference numerals represent similar parts throughout theseveral views of the drawings, and wherein:

FIG. 1 shows a schematic illustration of a knitted fabric; and

FIG. 2 shows a schematic illustration of a guide bar configuration forproducing the knitted fabric according to FIG. 1.

DETAILED DESCRIPTION OF THE EMBODIMENTS

The particulars shown herein are by way of example and for purposes ofillustrative discussion of the embodiments of the present invention onlyand are presented in the cause of providing what is believed to be themost useful and readily understood description of the principles andconceptual aspects of the present invention. In this regard, no attemptis made to show structural details of the present invention in moredetail than is necessary for the fundamental understanding of thepresent invention, the description taken with the drawings makingapparent to those skilled in the art how the several forms of thepresent invention may be embodied in practice.

FIG. 1 shows a knitted fabric 1 in a highly schematized form. Theillustration is not to scale.

Knitted fabric 1 is formed in that multiple warp threads running inlongitudinal direction 2 are connected to one another by stitches.

Knitted fabric 1 includes a, e.g., one, section embodied as a spacerfabric 3, a, e.g., one, section embodied as a single-ply fabric 4 and a,e.g. one, section embodied as a tubular fabric 5 arranged consecutivelyin longitudinal direction 2.

Single-ply fabric 4 is embodied as a one-by-one rib knitted fabric.Further, single-ply fabric 4 is arranged between spacer fabric 3 andtubular fabric 5.

The three sections, that is, spacer fabric 3, single-ply fabric 4 andtubular fabric 5, are formed by continuous warp threads, i.e., noadditional measures are used for these three sections be joinedtogether.

To produce a knitted fabric 1 of this type, a guide bar arrangement suchas illustrated schematically in FIG. 2 can be used.

For example, a guide bar GB1 lays down a front surface layer 6. Guidebars GB7 and GB8 lay down threads for a rear surface layer 7. A guidebar GB6 lays down pile threads 8, which can also be referred to “spacerthreads,” as shown in FIG. 1. Furthermore, four jacquard bars JB2, JB3,JB4 and JB5 are provided which can be controlled so that they eithersubject a warp thread to a stitch formation or remove a warp thread fromstitch formation during a stitch formation process.

Instead of guide bar GB6, jacquard bars JB2-JB5 can also be used to laydown the pile threads 8.

To create two surface layers 6, 7, a double-section warp knittingmachine is used, that is, a warp knitting machine with two needle bedsfor knitting needles.

Single-ply fabric 4 is embodied as what is referred to as a “simplex”fabric. A single-ply fabric 4 of this type comprises the two surfacelayers 6, 7 which, however, bear directly against one another and arealso connected to one another during the stitch formation processes. Thetwo layers 6, 7 are therefore closely and inextricably connected.

The tubular fabric 5 is essentially also composed of the two surfacelayers 6, 7, which are only directly connected to one another at thelongitudinal edges running in the longitudinal direction 2.

Knitted fabric 1 with the three different fabric sections (or types) canthus be produced based upon knitting technology with a machine havingtwo needle beds and at least four independent thread-feeding elements.In an exemplary embodiment, the thread-feeding elements are, at least inthe case of the jacquard bars JB2-JB5, based on a piezo jacquardtechnology. The arrangement of the jacquard elements is thereby chosensuch that the jacquard bars JB2-JB5 can be used both for forming pilesand for patterning surfaces. The different sections with pile (spacerthread 3), simplex (single-ply fabric 4) and tube (tubular fabric 5) canthus be reproduced in a single product.

The knitted fabric illustrated can then be further processed for anumber of textile products. This will be described below on the basis ofa holder for a delicate object, for example a mobile phone.

Tubular fabric 5 forms a holder with an open front side 9, through whichthe telephone can be inserted.

Single-ply fabric 4, which in a manner of speaking closes the holder atthe bottom end, connects to tubular fabric 5 so that the insertedtelephone is not able to fall out in a downward direction. Spacer fabric3 can be folded over onto tubular fabric 5 to pad the outside of tubularfabric 5. In this embodiment, it is preferred that spacer fabric 3 has agreater extension in the longitudinal direction 2 than tubular fabric 5.This extension can even be at least twice as large as the extension oftubular fabric 5 in longitudinal direction 2. It is thus possible tohave spacer fabric 3 run along one side of tubular fabric 5 and, after afolding-over of spacer fabric 3, to fold it back down on the other sideof tubular fabric 5. Spacer fabric 3 then also closes the opening of afront side 9. The holder that is formed by tubular fabric 5 is thenautomatically padded on all sides, since spacer fabric 3 with pilethreads 8 is capable of absorbing certain impacts and pressures.

Single-ply fabric 4 is arranged roughly in the middle of spacer fabric3, that is, spacer fabric 3 is arranged symmetrically to single-plyfabric 4 in the thickness direction. In this case, however, it issufficient if single-ply fabric 4 is arranged within a range of 40% to60% of the thickness of spacer fabric 3. The thickness is the distancebetween front surface layer 6 and rear surface layer 7.

In another embodiment not illustrated, single-ply fabric 4 can alsoconnect to spacer fabric 3 in such a manner that single-ply fabric 4 isthe continuation of one of the two surface layers 6, 7.

Single-ply fabric 4 preferably forms not only the bottom closure of thepouch or bag that is formed by tubular fabric 5, but rather also forms atype of hinge. Accordingly, it is beneficial if single-ply layer 4 hasan extension in longitudinal direction 2 that is at least as large as athickness of spacer fabric 3 that protrudes past single-ply fabric 4. Itis thus ensured that spacer fabric 3 can be folded over onto tubularfabric 5 without any problems occurring.

If it is known how “thick” the filled holder formed by tubular fabric 5is, which is normally the case if a holder of this type is finished fora specific product, then it is also beneficial if single-ply fabric 4has an extension in longitudinal direction 2 that is at least as largeas a thickness of the tube formed by tubular fabric 5. In this case, itis also ensured that spacer fabric 3 can be folded over all the way tothe long side of tubular fabric 5 by single-ply fabric 4.

Spacer fabric 3 can have different thicknesses transversally tolongitudinal direction 2. In this case, spacer fabric 3 and theaccompanying padding effect can be adapted to the object that is to beaccommodated in tubular fabric 5 if tubular fabric 5 is used for a bagor pouch. For example, a greater thickness of spacer fabric 3 can beprovided in particularly delicate regions of the object to allow thesesections to be better protected.

The illustrated arrangement of spacer fabric 3, single-ply fabric 4 andtubular fabric 5 is shown merely by way of example. It can also beprovided that a section with spacer fabric 3 is arranged on one side ofa section with tubular fabric 5 and a section with single-ply fabric 4is arranged on the opposite side of tubular fabric 5. In the lattercase, a section with spacer fabric 3 can also be connected to thesection with single-ply fabric 4, for example, to cover both sides oftubular fabric 5 with shorter sections of spacer fabric 3.

Thus, a knitted fabric with three different functions or properties canbe produced without the need for a complicated retooling or finishing ofthe knitted fabric. This minimizes the finishing effort drastically andat the same time results in a decrease in production costs. The risk ofdefects during production is also reduced.

The thinner one-by-one rib passages can be easily draped. The surfacesof the individual structures can be freely designed. Patterns can beintegrated for functional zones with air permeability and for breathableregions with appropriate reinforcements, or the surface can be used forstyling the knitted fabric with colors and shapes. The arrangement ofthe warp weaving machine used permits any desired number of needles orthread-feeding elements necessary for the different regions. In thismanner, different structures can be worked not only in the direction ofproduction, but also in the width direction of the knitted fabric. Theinput and sequencing of the individual repeating patterns can beachieved by a pattern control processor, for example.

In addition to the holders described above, shoes, articles of clothing,backpacks, jackets, seating furniture and mattress materials, packaging,etc. can be produced.

It is noted that the foregoing examples have been provided merely forthe purpose of explanation and are in no way to be construed as limitingof the present invention. While the present invention has been describedwith reference to an exemplary embodiment, it is understood that thewords which have been used herein are words of description andillustration, rather than words of limitation. Changes may be made,within the purview of the appended claims, as presently stated and asamended, without departing from the scope and spirit of the presentinvention in its aspects. Although the present invention has beendescribed herein with reference to particular means, materials andembodiments, the present invention is not intended to be limited to theparticulars disclosed herein; rather, the present invention extends toall functionally equivalent structures, methods and uses, such as arewithin the scope of the appended claims.

What is claimed:
 1. A knitted fabric comprising: warp threads that runin a longitudinal direction and that are connected to one another by astitch formation; and at least three sections arranged consecutively inthe longitudinal direction, wherein the at least three sections compriseat least one section formed as a spacer fabric, one section formed as asingle-ply fabric and one section formed as a tubular fabric.
 2. Theknitted fabric according to claim 1, wherein the single-ply fabric isformed as a one-by-one rib knitted fabric.
 3. The knitted fabricaccording to claim 1, wherein the single-ply fabric is arranged betweenthe spacer fabric and the tubular fabric.
 4. The knitted fabricaccording to claim 3, wherein the spacer fabric has a larger extensionin the longitudinal direction than the tubular fabric.
 5. The knittedfabric according to claim 4, wherein the spacer fabric has an extensionin the longitudinal direction that is at least two times as large as theextension of the tubular fabric in the longitudinal direction.
 6. Theknitted fabric according to claim 1, wherein the spacer fabric issymmetrically arranged to the single-ply fabric in the thicknessdirection.
 7. The knitted fabric according to claim 1, wherein thesingle-ply fabric has an extension in the longitudinal direction whichis at least as large as a thickness of the spacer fabric that protrudespast the single-ply fabric.
 8. The knitted fabric according to claim 1,wherein the single-ply fabric has an extension in the longitudinaldirection which is at least as large as a thickness of a tube that isformed by the tubular fabric.
 9. The knitted fabric according to claim1, wherein the spacer fabric is arranged on one side of the tubularfabric and the single-ply fabric is arranged on an opposite side of thetubular fabric.
 10. The knitted fabric according to claim 1, wherein thespacer fabric comprises sections with different thicknessestransversally to the longitudinal direction.
 11. A method for producinga knitted fabric using two knitting needle heads and thread-feedingelements at least partially embodied as jacquard elements, comprising:forming piles or surfaces, depending upon a predetermined fabricstructure, by using at least four independent thread-feeding elementsand controlling the jacquard elements.
 12. The method according to claim11, wherein the jacquard elements are used to pattern at least onesurface.
 13. The method according to claim 11, wherein the jacquardelements are controlled varyingly during a stitch formation process. 14.The method according to claim 13, wherein different structures arecreated in the width direction of the knitted fabric.
 15. A method offorming a knitted fabric comprising: forming at least three sectionsconsecutively in a longitudinal direction along which warp threads arearranged to run, the at least three sections comprising a spacer fabricsection, a single-ply fabric section and a tubular fabric section,wherein, in forming the at least three sections, the warp threads areconnected to one another by a stitch formation.
 16. The method accordingto claim 15, wherein the spacer fabric section comprises a front surfacelayer and a rear surface layer connected by pile threads, wherein thesingle-ply fabric section comprises the front surface layer and the rearsurface layer, and the tubular fabric section comprises the frontsurface layer and the rear surface layer.
 17. The method according toclaim 16, wherein, in a machine with plural guide bars, a first guidebar lays down the front surface layer, a second guide bar lays down therear surface layer and a third guide bar lays down the pile threads. 18.The method according to claim 16, wherein, in a machine with pluralguide bars and plural jacquard bars, a first guide bar lays down thefront surface layer, a second guide bar lays down the rear surface layerand the plural jacquard bars lays down the pile threads.
 19. The methodaccording to claim 16, wherein, in a machine with at least two needlebeds and plural independent thread-feeding elements, the at least twoneedle beds form the front and rear surface layer and the pluralindependent thread-feeding elements form the pile layers.
 20. The methodaccording to claim 19, wherein the plural independent thread-feedingelements comprise at least four jacquard bars.